Fully integrated precast concrete construction including provisions for insulation and all services-HVAC, plumbing, lighting etc.

ABSTRACT

The integrated precast building system provides for all construction elements. The walls, floor, and roof form an integrated structure of module length (FIG.  3 ). Passages for HVAC, electrical wiring and piping are provided. Inserts for decorative panels and lighting are easily installed and removed. The sloped roof requires no covering. A flat roof can be made with the floor panel but the roof would not be as waterproof as the recommended sloped roof. The system is applicable to homes thru large commercial buildings. The building goes together faster and is completed quicker because all details of the structure are integrated. Life cycle costs are minimized because the structural elements need no painting and do not deteriorate. The basic structure is fireproof. Modifications are easy. Removing the inserts, installing the changes and replacing the inserts facilitate modifications. The buildings can withstand earthquake  4  requirements when post tensioned.

CROSS-REFERENCE TO RELATED APPLICATIONS

NONE

FEDERALLY SPONSORED RESEARCH

NONE

SEQUENCE LISTING OR PROGRAM

NONE

1. Prior Art

1. U.S. Pat. No. 1,123,261 Jan . 5, 1915 by T. A. Edison

Mold for Concrete Construction

This is the best example of fully integrated building system to date. Itwasn't precast but was cast as one unit in a single pour. The modelshown at the Edison National Historic Site shows how the building was tolook. The nearest example of the model home is 18 concrete homes builtabout 1915 in Newark, Ohio. They are similar in appearance to the modelbut the construction is not with the Edison forms. About the same time1919, cement homes were built in one day using wood forms in Union, N.J.All of the houses are still lived in and the owners in Newark, Ohio arevery happy with their homes.

The homes were not insulated and did not provide for utilities. Edisoncould not give away the patent because the cost of the forms precludedmaking a profit. No historical record was found of how the Newark, Ohiohomes were constructed but the developer was purported to be a friend ofEdison and some of Edison's forms may have been used. Conventional largeconcrete blocks were used in the foundation work. The owners of theUnion, N.J. homes complain of leaky roofs. This is not surprisingbecause the roofs were flat.

2. U.S. Pat. No. 1,144,038 Sep. 28, 1915 by W. C. Broughton—ConcreteBuilding.

This is an example of a simple concrete structure made of precastconcrete parts. It is not reinforced to modern standards and has noprovisions for utilities.

3. U.S. Pat. No. 1,479,557 Jan. 1, 1924 by W. R. Raymond—BuildingConstruction.

This is another example of simple concrete construction. It is makes noprovisions for utilities.

4. U.S. Pat. No. 1,924,801 Aug. 29, 1933 by R. C. Olmsted—Concretebuilding

This is a more advanced precast concrete system. It makes no provisionsfor utilities or insulation.

5. U.S. Pat. No. 4,071,984 Feb. 7, 1978 by Larrow—House assembly withprefabricated elements.

This is a more advanced system that does make provisions for insulationbut not utilities. It would not pass the latest earthquake requirements.It is not fireproof and is not of cast elements of precast concrete.

6. U.S. Pat. No. 4,114,333 Sep. 19, 1978 by Jones et al.—Wall Panel Unit

This is a limited use panel and does not represent an integratedbuilding system.

7. U.S. Pat. No. 4,127,971 Dec. 5, 1978 BUILDING CONSTRUCTED OF PRECASTL-SHAPED CONCRETE UNITS.

This is a limited system for one-story buildings. It makes no provisionsfor insulation or utilities. It is not earthquake resistant or adaptedto a wide range of structures.

8. U.S. Pat. No. 4,142,340 Mar. 6, 1979 by Howard BUILDING ENCLOSUREMADE FROM STANDARD CONSTRUCTION UNIT IN SIDE WALLS AND ROOF DECK

This is another limited system for one-story buildings. It makes noprovision for insulation or utilities. It is not earthquake resistant oradapted to a wide range of structures.

9. U.S. Pat. No. 4,158,941 Jun. 26, 1979 by Silvio Diano PRECASTBUILDING STRUCTURE AND METHOD OF ASSEMBLY

This is a circular structure that makes no provision of insulation orutilities. A much superior circular precast structure was built in theearly 60s by Don Johnson (Architect and builder) which required nocentral support but joined the roof sections by a post tensionedcircular beam. Don has built several precast circular buildings but theywere not fully integrated with built in channels for utilities. Circularbuildings are difficult to scale and forms have to be built for eachdiameter. This is very limiting and costly.

10. U.S. Pat. No. 4,252,767 Feb. 24,1981 by Matthew R. Piazza, Nichols;David E. Zimmer COMPOSITE BUILDING MODULE

This system makes no provision for utilities. It is not earthquakeproof. It has very limited applicability.

11. U.S. Pat. No. 4,669,240 Jun. 2, 1987 by Gluseppe Amormino PRECASTREINFORCED WALL PANELS AND METHOD OF ERECTING SAME.

This system makes no provision for utilities. It is not earthquakeproof. It has very limited applicability.

12. U.S. Pat. No. 5,072,554 Dec. 17, 1991 by Lowell K. HaymanPREFABRICATED MODULAR STORAGE BUILDING

This is a limited system for buildings that makes no provisions forinsulation or utilities.

13. U.S. Pat. No. 5,103,604 Apr. 14, 1992 by William Teron MODULARBUILDING SYSTEMS

This is an expansion of patent 4,127,971 and is a small improvement butmakes no provision for insulation or utilities except at specialmodules. It is not a complete building system and would not beearthquake resistant.

14. U.S. Pat. No. 5,150,552 Sep. 29, 1992 by Davis-Arzac BUILDING SYSTEMFOR EXTENSION OF PROGRESSIVE HOUSING

This is a limited application system for building extensions.

15. U.S. Pat. No. 5,230,191 Jun. 27, 1993 by Paul Mayrand PRECASTCONCRETE PANEL FOR PREFABRICATED BUILDING STRUCTURE

This is a sophisticated wall system that combines with floor slabs toerect buildings. Provision for utilities and rework after constructionis not provided. Connections do not seem to be strong enough to meetearthquake 4 requirements.

16. U.S. Pat. No. 5,440,845 Aug. 15,1995 by Maher K. Tadros; David C.Salmon; Amin Einea; Todd D. Culp PRECAST CONCRETE SANDWITCH PANELS

This is not a building system. It is a complex wall structure that wouldrequire skilled labor to construct.

17. U.S. Pat. No. 5,697,189 Dec. 16, 1997 by John F. Miller; Andrew JMiller LIGHTWEIGHT INSULATED CONCRETE WALL

This is not a building system. It is a complex wall structure that wouldRequire skilled labor to construct.

18. U.S. Pat. No. 6,076,319 Jun. 20, 2000 by Gary K. Hendershot, GregoryE. Cook PRECAST CONCRETE CONSTRUCTION AND CONSTRUCTION METHOD

This is an elaborate system that makes no provision for insulation andutilities. Erection is not simple and connections are varied and may notmeet earthquake 4 requirements.

BACKGROUND OF THE INVENTION OBJECTS and ADVANTAGES

1. Satisfy the needs of buildings from modest homes through multistorycommercial buildings of the most common configurations.

2. Be fireproof.

3. Be compatible with earthquake prone locations without extensivemodifications.

4. Blend well with existing structures at the building locations.

5. Provide the ability to have unique appearances that will beattractive and useful.

6. Allow the owners considerable choices for customizing the appearanceand functionality of the building.

7. Require minimum maintenance.

8. Initial construction cost shall be no more than existing constructionas a requirement and considerably less than conventional as a goal.

9. Construction time is minimized.

10. Skilled craftsmen requirements are minimized.

11. Training of the construction crew is easily accomplished withworkmen of minimum skills supervised by a permanent small skilledworkforce.

12. Quality control shall be inherent in the process and easilyinspected.

13. All system elements shall be compatible with the uniform buildingcode.

14. Structural members shall provide the finished surfaces of thebuilding. No cladding shall be required.

15. The floors and roofs shall be free span up to 42 feet. Larger spansare possible but not considered. For very large free span buildingsother building systems are more appropriate.

16. Insulation shall be designed into the structural modules.

17. Doors and windows openings shall be precision sized with allsurfaces finished during the casting process.

18. Lighting shall be indirect, efficient and capable of adequateswitching.

19. The electrical system is designed into the structural modules.

20. HVAC shall be incorporated into the building design and not tackedon later. All ductwork, controls etc. shall be included in the detaildesign of the building.

21. The system uses a seven-foot module but other modules could beaccommodated. The uniqueness of the system is in its completeness andnot in the module size.

22. The basic modules are wall, floor and roof.

23. The system can be erected in 7-foot increments up to 42 foot inwidth. The length of the building is N×7 feet.

24. The roof can be flat or sloped. The sloped roof can be designed toany desired pitch. No roof covering is required for any slope over 2/12.The roof life is unlimited and maintenance free. The preferredembodiment shows a 4/12 slope.

25. The foundation is designed for each site and depends on soilconditions, height of the building and other building unique features.It will be part of each building unique engineering designcertification.

26. Cavities under the basement floor and in the building modulesprovide connectivity for all the utilities, electrical, HVAC, andcommunications.

Further objects and advantages of my invention will become apparent froma consideration of the drawings and ensuing description.

SUMMARY

1. The building system is fully integrated. Walls, floors, and roof aredesigned to join each other and provide passages for heating, lighting,air conditioning, and plumbing. Such passages can be used after thebuilding is finished. Modifications can use the wall, roof and floorpassages for economical changes without disturbing the existing buildingtenants. Lighting fixtures are designed to fit the floor and roofmodules. Floor, and roof coffers are designed to receive the lightingfixtures and standard decorative ceiling tile. Wall coffers can receivedecorative panels of varying designs. All modules can receive electricaloutlets, switches, etc.

2. All structural elements of the building are fireproof.

3. The building system can produce multiple types of buildings fromhomes to high rise buildings.

BRIEF DESCRIPTION OF DRAWINGS

1. FIG. 1—Prototype house isometric

a. FIG. 1 a—Main floor plan

b .FIG. 1 b—Lower floor plan

2. FIG. 2—Large building

a. FIG. 2 a—Condo building project

3. FIG. 3—Basic modules

a. FIG. 3 a—Foundation floor cross section

4. FIG. 4—Wall module details.

a. FIG. 4 a—Wall sections AA & CC

b. FIG. 4 b—Wall section BB details 1, 2, & 3

5. FIG. 5—Floor module details

a. FIG. 5 a—Floor cross sections

6. FIG. 6—Roof module details

a. FIG. 6 a—Roof cross sections

b. FIG. 6 b—Roof cross sections

c. FIG. 6 c—Roof overhang cross section

d. FIG. 6 d—Roof assembly details

7. FIG. 7—Jointing modules partial isometric

8. FIG. 8—Partial isometric with roof in place

a. FIG. 8 a—Roof detail isometric

9. FIG. 9—Stair module

a. FIG. 9 a—Stairs—Isometric cut away to show stairs

10. FIG. 10—Wall module with door

11. FIG. 11—Wall module with 4′×4′ window

12. FIG. 12—Wall module with 30″×4′ casement window

13. FIG. 13—Interior module

14. FIG. 14—Interior module with door

15. FIG. 15—Lighting details—Flat ceiling

a. FIG. 15 a-2 Lamp ceiling light

b. FIG. 15 a 1—Single lamp details

b. FIG 15 b—Cathedral ceiling light

c. FIG. 15 c—Cathedral ceiling light-design details

d. FIG. 15 d—Lighting sketch

e. FIG. 15 d 1—Wall lighting

f. FIG. 15 d 2—Sidewall lighting flat ceiling

16. FIG. 16—Heat, plumbing & electrical routing

17. FIG. 17—Heating and cooling under lower floor.

a. FIG. 17 a—Heating and cooling under lower floor

18. FIG. 18—Post tensioning

DETAILED DESCRIPTION Preferred Embodiment—FIGS. 1-18

FIG. 1 shows an isometric of the prototype house to be built on a slopedlot. This embodiment illustrates most of the system modules. Itillustrates the versatility of the system to accommodate terrainelevations over the building length. Surface textures can be varied. Asan example, a rock surface is easily applied while the wall section iscuring in a horizontal position in the form during the curing process.This is easily done with unskilled labor using rock rubble that is themost economical rock to buy. Don Johnson and his children rocked thesurfaces of his precast concrete home in this manner in a few hours veryeconomically. No skilled masons were present to help. Stamping of theoutside surface during curing is also a possibility. There are numerouspatterns available. Staining of the surface eliminates the need forpainting. White and colored concrete can also be used in the process.These processes are in the public domain and are not part of thispatent. This patent does allow economical use of many available surfacefinishes in an economical manner.

FIG. 1A is the first floor plan of the prototype house. Because of the42-foot free span interior arrangements can be easily accommodated.Cabinetry is used for most of the walls. Where the internal wall systemis used, the walls are placed on the module lines that form a3.5-foot×3.5-foot grid. Opening the floor panel accommodates theinstallation of the stairs. Some of the upper stairs are located in thefloor beam that supports the upper end of the stairs. FIG. 9 illustratesthe installation of the stairs in the floor opening. The cross passagethru the floor is routed to the adjacent passage in the same floormodule thru openings blocked out of the central leg of the floor panelalong the neutral axis of the structural leg.

FIG. 1B is the lower floor plan of the prototype house. The 3.5 footgrid is adhered to in placing the internal walls. Utility and HVACconnecting passages are located under the floor. FIGS. 17 and 17A showstandard construction under the floor of a rectangular building. FIG. 17b shows the passages under the floor in the prototype house allowing theHVAC unit to be located in the utility and laundry room under thegarage. Each building HVAC would be designed to meet the requirements ofthat building but would be consistent with the system design asillustrated in the patent application.

FIG. 2 and FIG. 2A show sketches of large buildings that are possible.Large buildings such as stores, warehouses, shops, office buildings, andany other rectangular building is possible. The practical limitation onheight is probably about 10 stories.

FIG. 3 illustrates a basic 7-foot module of walls, floor and roof. A7-foot module is used in the preferred embodiment but other module sizesusing the system are possible. The system uniqueness is in itscompleteness and not in the module size.

FIG. 3A shows a generic foundation and the composition of the lowerfloor. The rock bed is used as a passive element in the HVAC system.Each building HVAC would be designed to use passive heat and cooling asmuch as possible depending on the site conditions. Standard HVACelements would be used and could adequately condition any buildingeconomically.

FIG. 4 shows the wall section of the 2-story prototype building.

FIG. 4A shows the wall cross sections in greater detail.

FIG. 4B shows the wall section BB details.

FIG. 4C shows a 3 story wall section. 5 story wall sections arepractical using a 60-foot mold. Taller buildings are best erected withthe upper walls erected from the 5th floor. The system is practical upto 15 floors restaging every 5 floors. Buildings over 10 stories requiremore study. They fit into the system but very tall buildings havespecial problems and other systems might be more economical.

FIG. 5 shows the floor module. The length shown is 42 feet but anymodular size up to 42 feet can be made in the mold.

FIG. 5 a shows the cross sections of the floor.

FIG. 6 shows the roof module. The roof and floor modules are similar andcan be made in the same mold bed. The module shown is for 42 foot clearspan. Shorter modular spans can be made in the same mold.

FIG. 6 a shows the roof cross sections and they are similar to the floorcross sections.

FIG. 6 b shows the roof cross sections at the angle they will beinstalled to make the roof.

FIG. 6 c shows the roof overhang cross-section.

FIG. 6 d shows the assembly of the roof. The center tie post-tensionedcable allows the erection of the roof without a ridge beam. This makesit possible to make almost any length of building desired because eachmodularly assembled section is self-supporting. The cross tensioningdone after the building is erected ties the whole building together andkeeps all the concrete surfaces in compression. This compression makesthe surfaces waterproof. It also makes it possible to design thebuilding to earthquake 4 stresses.

FIG. 7 shows the jointing modules that complete the building and alsoallow all the walls to be the same height. It is possible to design abuilding with varying height wall sections and eliminate the gussets. Itwould be more costly and complicate the erection and post tensioningprocess.

FIG. 8 shows the roof in place with the overhang and jointing modules.

FIG. 8 a shows the special overhang module and filler module over theconnection wall to the garage.

FIG. 9 shows the stair module shown right and left hand. Prefabricatedstairs have been used since the early 1900s. The attachment to the flooris made by blockouts in the floor module as shown in phantom.

FIG. 9 a shows the installation of the stairs in the prototype building.

FIG. 10 shows the wall module with a door installed.

FIG. 11 shows the wall module with a 4′×4′ window installed.

FIG. 12 shows the wall module with a 30″×4″ casement window installed.

FIG. 13 shows the interior wall module. The interior wall module isdesigned to continue the wall panel design of the exterior walls. It isdesigned to accept electrical outlets and switches.

FIG. 14 show the interior wall module with a door installed.

FIG. 15 shows the basic preferred lighting for a flat ceiling in thebottom of the floor module.

FIG. 15 a shows the technical details of the collimated light fixturefor a flat ceiling. The efficiency of the unit is the % of the lightthat is collimated. The rest of the light is not lost but is radiated ina standard manner and its intensity diminishes with the square of thedistance from the light element.

FIG. 15 a 1 shows the technical details of a single lamp installation.This design is utilized for the roof overhang and illumination of theoutside walls where desired.

FIG. 15 b shows the light used in the cathedral ceiling.

FIG. 15 c shows the technical details of the cathedral ceiling light.

FIG. 15 d shows the illumination of the outside walls where desired.

FIG. 15 d 1 shows the wall lighting detail at the cathedral ceilinglevel.

FIG. 15 d 2 shows the wall lighting detail at the flat ceiling level.

FIG. 16 shows the routing channels for HVAC, plumbing and electrical.All openings in the walls, floor, and ceilings are covered with standardpanels, decorative panels, and lighting panels. Great flexibility inallowed in decorating. Large selections of decorative ceiling panels areavailable. The wall panels are standardized as much as possible and onlarge projects the panels can be ordered in the custom size to eliminatethe cost of waste and reduce on site labor. All modern surfacetreatments can be accommodated without excessive costs. Duringmodifications, necessary panels are removed without disturbing thebuilding tenants to the degree that standard building constructionmodifications cause.

FIG. 17, 17 a & 17 b show the ductwork that has to be made in thebasement floor. The rock bed under the floor is used for coolingassistance in the summer. Low heat loss in the building allow foreconomical HVAC to be installed.

FIG. 18 illustrates the post tension channels available in thestructure. Each building is engineered for site conditions and themodules used. Standard post tension engineering is used to make thebuilding earthquake resistant to earthquake zone 4 requirements.

Conclusion, Ramification, Scope

The invention is an integrated building system that will cutconstruction costs, reduce lifetime costs and greatly reducemodification costs. The basic structure is fireproof and makesprovisions for HVAC, lighting, plumbing and most surface finishingtechniques.

The system is applicable to most residential and commercialconstruction. It requires a reasonable sized project to accommodateconstruction on site. The cost of setup and termination must be factoredinto the overall cost of the project. The forms and machinery would bemoved from project to project and their cost amortized over the life ofthe forms and machinery. All maintenance supplies, engineering, laborand site dependent costs would be charged to each project. Low costhousing would be possible with the system and would make many projectscost effective. Standard and luxury projects would benefit by providingmany extras at the cost of comparable projects without the extras. Allprojects would benefit by extended life and durability of the concretestructure.

The scope of the system is universal and when demonstrated would beimitated. A major change in building technique is required as landbecomes more costly and the population grows. Present demand is greatbut the cost for first time homebuyers is a real barrier to goodhousing. Many commercial enterprises would benefit by lower costbuildings and insurance reductions because of the buildings basic fireresistance and durability. Changes in usage would be accommodated easilyand encourage business to modify their operations for greaterefficiency.

1. The building system is fullly integrated. Walls, floors, and roof aredesigned to join each other and provide passages for heating, lighting,air conditioning, and plumbing. Such passages can be used after thebuilding is finished. Modifications can use these passages foreconomical changes without disturbing the existing building.
 2. Allstructural elements of the building are fireproof
 3. The building systemcan produce multiple types of buildings from homes to high risebuildings.